Layered earplug

Abstract

A novel earplug comprising a stack of thin flexible plastic discs bonded together about a central hole and loose at the edges is formed with a central core or plug forming a nose or bumper and a handle tail. The configuration described permits easy insertion and removal from the ear and the multiple disc structure forms a barrier to the entry of acoustic noise into the ear canal.

What is claimed is: 
     
       1. An earplug for insertion into the exterior opening of the auditory canal of a person to prevent undesired intrusions into the canal which comprises: a plurality of thin, flexible, discs stacked one on top of another to form a body portion;   a hole pierced in each disc forming a bore along a longitudinal axis of the body portion;   bonding means securing the edges of the holes pierced in said discs to one another throughout the bore of the stack of discs;   auxiliary barrier means inserted in the bonded bore in the stack of discs for preventing undesired sound or fluid from penetrating into the auditory can through the bore.   
     
     
       2. An earplug according to claim 1 wherein said auxiliary barrier means comprises an elongated rivet-like member having a round head at one end inserted in the bore, said member being formed of a foam material with the head abutted against one end of the stack discs. 
     
     
       3. An earplug according to claim 2 wherein said auxiliary barrier means includes an enlarged second round head member formed on said rivet-like member at the end opposite the rivet head end to securely hold the plurality of stacked discs together. 
     
     
       4. The earplug according to claim 2 further including said round head of the rivet-like member being positioned at the end of the ear plug to be inserted into the ear of a user and the rivet extending outwardly from the other earplug end to form a tab for inserting and removing the earplug from an ear of a user. 
     
     
       5. An earplug according to claim 1 wherein said auxiliary barrier means comprises an ear tube from an audio listening device. 
     
     
       6. An earplug according to claim 1 wherein said bonding means comprises an adhesive for joining adjacent discs together around the bore of the stack. 
     
     
       7. An earplug according to claim 1 wherein said discs are bonded together adjacent to the hole by thermal fusion of the discs to each other throughout the length of the bore formed in said body portion. 
     
     
       8. The earplug of claim 1 wherein at least one surface of said discs is a smooth, low sliding-resistance surface so that said ear plug may be easily inserted with minimal frictional resistance. 
     
     
       9. The earplug according to claim 8 wherein said discs are smooth polyethylene. 
     
     
       10. The method of forming an earplug which comprises the steps of: piling up a plurality of thin flexible discs to form a stack;   compressing said stack of discs a predetermined amount;   piercing a hole through a longitudinal axis of said stack of discs;   binding the circumference of the pierced holes in said stack of discs together to form a bore; and   filling the hole in said stack of discs with a barrier material.   
     
     
       11. The method according to claim 10 further including varying the compressing of the stack of discs to vary the flexibility of the stack of discs so that said stack may be readily inserted in an ear of a user and held therein. 
     
     
       12. The method according to claim 10 further including forming said stack of discs into a cylindraform body having a substantially solid center and flexible edges. 
     
     
       13. The method according to claim 10 further including forming said stack of thin flexible discs from sound attenuating material to provide a desired amount of sound attenuation for a user. 
     
     
       14. The method according to claim 10 further including forming said stack of thin flexible discs from a fluid sealing material so that upon insertion in the auditory canal of a user, undesired fluid is sealed from entry therein. 
     
     
       15. The method of forming an earplug comprising the steps of: piling up a plurality of thin flexible circular discs to form a cylindrical stack;   compressing said stack of discs a predetermined amount of compression;   piercing a hole through said cylindrical stack of circular discs along the axis thereof;   filling the hole in said stack with a barrier material;   forming a cap member at each end of said barrier material to hold said compressed stack of discs in said predetermined amount of compression.   
     
     
       16. An earplug according to claim 1 wherein said thin flexible discs are circular forming a cylindrical body. 
     
     
       17. An earplug according to claim 16 wherein said hole pierced in each disc is a circular hole forming a cylindrical bore in said stack of circular discs. 
     
     
       18. An earplug according to claim 10 including forming said flexible discs in circular configuration to form a cylindrical stack. 
     
     
       19. An earplug for use on the tip of an ear tube of a stethoscope or audio headset to prevent undesired intrusions into the auditory canal of a user which comprises: a plurality of thin, flexible, discs stacked one on top of another to form a body portion;   a hole pierced in each disc forming a bore along a longitudinal axis of the body portion;   bonding means securing the edges of the holes pierced in said discs to one another throughout the bore of the stack of discs; and   said bore being sized to receive therein the ear tube of the stethoscope or audio headset to form auxiliary barrier means in the bonded bore in the stack of discs for preventing undesired sound or fluid from penetrating into the auditory canal of the user through the bore.